Method for Manufacturing Waterproof Footwear

ABSTRACT

The invention provides a method of manufacturing waterproof shoe component and footwear using the same. The method includes the steps of, attaching a TPU waterproof and breathable membrane on an ordinary cloth, processing to get fabric A; attaching a layer of TPU waterproof and breathable membrane on an ordinary cloth, then attaching a layer of TC cloth on the TPU layer, processing to get fabric B; using fabric A or fabric B to stitch a sleeve, which matches with a pre-designed shoe pattern; making a shoe mould according to the shape of the pre-designed shoe pattern, in which the sleeve can coat on cutting fabric A into a number of straps according to the numbers of the stitching lines on the sleeve, seamless stitching the straps into a whole case along the distribution of the stitching lines; then coating the whole case onto the sleeve, with the TPU layer of the case adown and covering the stitching lines; putting the sleeve that covered the case into the shoe mould, then use the hot press molding by putting the shoe into a high frequency hot press machine to get into shape.

CROSS REFERENCE TO RELATED APPLICATIONS

This non-provisional patent application claims priority under 35 U.S.C. §119(a) from Patent Application No. 12104255.8 filed in Hong Kong, China on Apr. 30, 2012.

FIELD OF THE INVENTION

The present invention relates to the fields of clothing, shoes and hats, more particularly, relates to a method for manufacturing waterproof footwear.

BACKGROUND OF THE INVENTION

Waterproof boots are widely used in daily life and in many special circumstances, and usually there are three ways to manufacture waterproof boots, one is sewing waterproof fabric on shoes and boots, and then sizing in some seam position to strengthen the waterproof performance. The second is using waterproof material to produce the shoes first, and then use plastic to glue it on the shoe sole or case. As an improvement of the second method, there also a heat press molding method to form shoe soles and uppers in one piece by using plastic material. The third way is, stitching waterproof shoe cover with waterproof fabric first, then attaching waterproof membrane and cloth along the edges of the seams, and then pressing the membrane and cloth onto the edges by way of hot air welding, after waterproof footwear were made, equipping it with soles and uppers to make the corresponding shoes, the shoe would then become both waterproof and breathable. But all these methods have their own defects. For the first method, despite the sizing treatment, the existence of the seam would still render the shoe some difficulties in complete waterproofing, thus affecting the life of the waterproof shoes. For the second method, using plastic as waterproof material would normally render the shoes bad breathability and is therefore not suitable for constant-wearing users. While for the third method, the existing hot air welding technology depends on manual operation a lot. Faults and instability are therefore inevitable. Since the technology is only capable for stitching straight line but is unable to stitch curve nor create solid forming, it is incapable of processing footwear with complex sewing.

SUMMARY OF THE INVENTION

The present invention provides a method for manufacturing waterproof footwear, realizing the one-off overall hot pressing formation of waterproof footwear which is suitable for the manufacturing of shoes with complex and irregular seaming.

Accordingly, in one aspect thereof, the present invention provides a method of manufacturing waterproof footwear, comprises the steps of:

-   -   fabrics attaching: attaching a TPU (Thermoplastic polyurethane)         waterproof and breathable membrane on an ordinary cloth,         processing to get fabric A; attaching a layer of TPU waterproof         and breathable membrane on an ordinary cloth, then attaching a         layer of TC (Terylene Cotton) cloth on the TPU layer, processing         to get fabric B;     -   making sleeve: using fabric A or fabric B to stitch a sleeve,         which matches with a pre-designed shoe pattern;     -   making shoe mould: making a shoe mould according to the shape of         the pre-designed shoe pattern, in which the sleeve can coat on;     -   coating shoe stretch: cutting fabric A into a number of straps         according to the numbers of the stitching lines on the sleeve,         seamless stitching the straps into a whole case along the         distribution of the stitching lines; then coating the whole case         onto the sleeve, with the TPU layer of the case adown and         covering the stitching lines;     -   hot-press molding: putting the sleeve that covered the case into         the shoe mould, then use the hot press molding by putting the         shoe into a high frequency hot press machine to get into shape.

Preferably, the step of hot-press molding further includes the steps of pre-heating, welding, and hot pressing.

Preferably, the parameters of hot-press molding are as pre-heating for 0 to 10 seconds, welding for 15 to 35 seconds, hot pressing under temperature of 150° C. (centigrade) to 280° C. for 5 to 10 seconds.

Preferably, the shoe mould includes four detachable portions, which are upper mould, lower mould, right mould and left mould.

Preferably, the steps of pre-heating, welding, and hot pressing further including pre-heating, welding, and hot pressing on upper and lower moulds, pre-heating, welding, and hot pressing on right and left moulds.

Preferably, the parameters of pre-heating, welding, and hot pressing of upper and lower moulds are as pre-heating for 0 to 5 seconds, welding for 0 to 15 seconds, hot pressing under temperature of 150 to 280 for 0 to 5 seconds.

Preferably, the parameters of pre-heating, welding, and hot pressing on right and left moulds are as pre-heating for 0 to 5 seconds, welding for 0 to 20 seconds, hot pressing under temperature of 150 to 280° C. for 0 to 5 seconds.

Preferably, the pre-designed shoe pattern is toed shoe pattern.

Preferably, the toed shoe pattern has one toe, two toes, three toes, four toes or five toes.

Preferably, the distribution of the stitching lines on the toes is along the direction from toe cap to toe wrap.

Another purpose of this invention is to provide a type of waterproof footwear which is light, waterproof, durable and breathable.

In order to achieve the invention purpose, the technology this invention adopted is: a type of waterproof footwear, including the shoe sole and shoe case produced by the abovementioned methodology. Such waterproof footwear also includes shoe upper and/or accessories covering the said footwear.

By implementing the invention, in the manufacture of waterproof footwear, the traditional upper stitching and sizing process are eliminated, ensuring uppers with good air ventilation and good waterproof performance. The method overcomes the defect of poor ventilation property in footwear manufacturing by plastic materials; and most importantly, the method is particularly suitable for manufacturing for multiple sewing, irregular shape and complex seaming of waterproof footwear. By this method, the stitching lines can be wholly covered; the process is simple and easy to control, and with high yield.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present invention are described, by way of example only, with reference to the drawings, in which identical or related structures, elements, or parts may be labeled with the same reference numerals throughout the figures. Dimensions of components and features shown in the figures are generally chosen for convenience and clarity of presentation and are not necessarily to scale.

FIG. 1 shows a process flow diagram of the method of manufacturing waterproof footwear according to the present invention.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

Various embodiments of the present invention are described, by way of example only, with reference to the drawings.

As shown in FIG. 1, the method of manufacturing waterproof footwear provides in the present invention including the following steps:

fabrics attaching: attaching a TPU (Thermoplastic polyurethane) waterproof and breathable membrane on an ordinary cloth, processing to get fabric A; attaching a layer of TPU waterproof and breathable membrane on an ordinary cloth, then attaching a layer of TC (Terylene Cotton) cloth on the TPU layer, processing to get fabric B;

making sleeve: using fabric A or fabric B to stitch a sleeve, which matches with a pre-designed shoe pattern;

making shoe mould: making a shoe mould according to the shape of the pre-designed shoe pattern, in which the sleeve can coat on;

coating shoe stretch: cutting fabric A into a number of straps according to the numbers of the stitching lines on the sleeve, seamless stitching the straps into a whole case along the distribution of the stitching lines; then coating the whole case onto the sleeve, with the TPU layer of the case adown and covering the stitching lines;

hot-press molding: putting the sleeve that covered the case into the shoe mould, then use the hot press molding by putting the shoe into a high frequency hot press machine to get into shape.

Different example has different technological parameters, various embodiments will be described in the following.

EXAMPLE 1 Manufacturing of Toeless Footwear

Fabrics attaching: attaching a TPU (Thermoplastic Polyurethane) waterproof and breathable membrane on an ordinary cloth, processing to get fabric A; attaching a layer of TPU waterproof and breathable membrane on an ordinary cloth, then attaching a layer of TC (Terylene Cotton) cloth on the TPU layer, processing to get fabric B;

Making sleeve: using fabric A or fabric B to stitch a sleeve, which matches with a pre-designed shoe pattern;

making shoe mould: making a shoe mould according to the shape of the pre-designed shoe pattern, in which the mould can coat on;

Coating shoe stretch: cutting fabric A into a number of straps according to the numbers of the stitching lines on the sleeve of the toeless shoes, seamless stitching the straps into a whole case along the distribution of the stitching lines; then coating the whole case onto the sleeve, with the TPU layer of the case adown and covering the stitching lines;

Hot-press molding: putting the sleeve that covered the case into the shoe mould, then use the hot press molding by putting the shoe into a high frequency hot press machine to get into shape. The step of hot-press moulding further include the steps of pre-heating, welding, and hot pressing, and further divided into the steps of upper and lower moulds hot press molding, right and left moulds hot press molding. The detailed technological parameters of hot press molding are provided in table 1.

TABLE 1 Temperature on upper mould: Temperature on left mould: 150° C. 150° C. Temperature on lower mould: Temperature on right mould: 150° C. 150° C. Duration of pre-heating on upper Duration of pre-heating on right and lower moulds: 3 seconds and left moulds: 2 seconds Duration of hot pressing on upper Duration of hot pressing on right and lower moulds: 5 seconds and left moulds: 5 seconds Duration of welding on upper Duration of welding on right and lower moulds: 15 seconds and left moulds: 20 seconds

EXAMPLE 2 Manufacturing of Toed Footwear

In this example, the shoe pattern will have one toe, or two or three or four or five toes, as the pattern is toed shoe, during footwear stitching, the positions of the stitching lines should be strictly restricted, and the distribution of the stitching lines on the toe should along the direction of from toe cap to toe wrap, other than along the middle of two toes, in order to facilitate subsequent stitching and coating, so as to improve the quality. Moreover, the fabric of the sleeve can be “ordinary cloth+TPU layer+TC cloth” or “ordinary cloth+TPU layer”, and the fabric of the whole case is “ordinary cloth+TPU layer”.

Other steps of this example are similar with example 1, and the detailed technological parameters hot press molding are provided in table 2.

TABLE 2 Temperature on upper mould: Temperature on left mould: 200° C. 200° C. Temperature on lower mould: Temperature on right mould: 200° C. 200° C. Duration of pre-heating on upper Duration of pre-heating on right and lower moulds: 2 seconds and left moulds: 1 seconds Duration of hot pressing on upper Duration of hot pressing on right and lower moulds: 4 seconds and left moulds: 3 seconds Duration of welding on upper Duration of welding on right and lower moulds: 15 seconds and left moulds: 15 seconds

EXAMPLE 3

The steps of this example are similar to example 1 or 2, and the detailed technological parameters hot press molding are provided in table 3. The shoe pattern is not limited to toed or toeless shoes.

TABLE 3 Temperature on upper mould: Temperature on left mould: 250° C. 250° C. Temperature on lower mould: Temperature on right mould: 250° C. 250° C. Duration of pre-heating on upper Duration of pre-heating on right and lower moulds: 1 seconds and left moulds: 1 seconds Duration of hot pressing on upper Duration of hot pressing on right and lower moulds: 3 seconds and left moulds: 2 seconds Duration of welding on upper Duration of welding on right and lower moulds: 10 seconds and left moulds: 10 seconds

EXAMPLE 4

The steps of this example are similar with example 1 or 2, and the detailed technological parameters hot press molding are provided in table 4. The shoe pattern is not limited to toed or toeless shoes.

TABLE 4 Temperature on upper mould: Temperature on left mould: 280° C. 280° C. Temperature on lower mould: Temperature on right mould: 280° C. 280° C. Duration of pre-heating on upper Duration of pre-heating on right and lower moulds: 0 seconds and left moulds: 1 seconds Duration of hot pressing on upper Duration of hot pressing on right and lower moulds: 3 seconds and left moulds: 2 seconds Duration of welding on upper Duration of welding on right and lower moulds: 10 seconds and left moulds: 5 seconds

Performance Test

The properties testing results of waterproof, firmness and strength and moisture permeability of examples 1 to 4 are listed in table 5 as below.

TABLE 5 Properties Firmness and Moisture Waterproof Strength Permeability Example 1 15000/mmHg Bends for 60000  900-1000 g/m² times without split Example 2 10000/mmHg Bends for 25000 4000-5000 g/m² times without split Example 3 10000/mmHg Bends for 20000 6000-7000 g/m² times without split Example 4 10000/mmHg Bends for 20000 9000-10000 g/m²  times without split

The method of the present invention could be used to manufacture shoe components, such as shoe covers, shoe soles, shoe cases, shoe uppers, and/or boots.

Although the invention is described with reference to one or more preferred embodiments, it should be appreciated by those skilled in the art that various modifications are possible. Therefore, the scope of the invention is to be determined by reference to the claims that follow.

In the description and claims of the present application, each of the verbs “comprise”, “include”, “contain” and “have”, and variations thereof, are used in an inclusive sense, to specify the presence of the stated item but not to exclude the presence of additional items. 

What is claimed is:
 1. A method of manufacturing waterproof footwear, comprises the steps of: fabrics attaching: attaching a TPU waterproof and breathable membrane on an ordinary cloth, processing to get fabric A; attaching a layer of TPU waterproof and breathable membrane on an ordinary cloth, then attaching a layer of TC cloth on the TPU layer, processing to get fabric B; making sleeve: using fabric A or fabric B to stitch a sleeve, which matches with a pre-designed shoe pattern; making shoe mould: making a shoe mould according to the shape of the pre-designed shoe pattern, in which the sleeve can coat on; coating shoe stretch: cutting fabric A into a number of straps according to the numbers of the stitching lines on the sleeve, seamless stitching the straps into a whole case along the distribution of the stitching lines; then coating the whole case onto the sleeve, with the TPU layer of the case adown and covering the stitching lines; hot-press molding: putting the sleeve that covered the case into the shoe mould, then use the hot press molding by putting the shoe into a high frequency hot press machine to get into shape.
 2. The method of claim 1, wherein the step of hot-press molding further including the steps of pre-heating, welding, and hot pressing.
 3. The method of claim 2, wherein the parameters of hot-press molding are pre-heating for 0 to 10 seconds, welding for 15 to 35 seconds, hot pressing under temperature of 150° C. to 280° C. for 5 to 10 seconds.
 4. The method of claim 2, wherein the shoe mould includes four detachable portions, which are upper mould, lower mould, right mould and left mould.
 5. The method of claim 4, wherein the steps of pre-heating, welding, and hot pressing further including pre-heating, welding, and hot pressing on upper and lower moulds, pre-heating, welding, and hot pressing on right and left moulds.
 6. The method of claim 5, wherein the parameters of pre-heating, welding, and hot pressing on upper and lower moulds are as pre-heating for 0 to 5 seconds, welding for 0 to 15 seconds, hot pressing under temperature of 150° C. to 280° C. for 0 to 5 seconds.
 7. The method of claim 5, wherein the parameters of pre-heating, welding, and hot pressing on right and left moulds are as pre-heating for 0 to 5 seconds, welding for 0 to 20 seconds, hot pressing under temperature of 150° C. to 280° C. for 0 to 5 seconds.
 8. The method of claim 1, wherein the pre-designed shoe pattern is toed shoe pattern.
 9. The method of claim 8, wherein the toed shoe pattern has one toe, two toes, three toes, four toes or five toes.
 10. The method of claim 8, wherein the distribution of the stitching lines on the toes is along the direction from toe cap to toe wrap.
 11. A method of manufacturing waterproof shoe component, comprises the steps of: fabrics attaching: attaching a TPU waterproof and breathable membrane on an ordinary cloth, processing to get fabric A; attaching a layer of TPU waterproof and breathable membrane on an ordinary cloth, then attaching a layer of TC cloth on the TPU layer, processing to get fabric B; making sleeve: using fabric A or fabric B to stitch a sleeve, which matches with a pre-designed shoe pattern; making shoe mould: making a shoe mould according to the shape of the pre-designed shoe pattern, in which the sleeve can coat on; coating shoe stretch: cutting fabric A into a number of straps according to the numbers of the stitching lines on the sleeve, seamless stitching the straps into a whole case along the distribution of the stitching lines; then coating the whole case onto the sleeve, with the TPU layer of the case adown and covering the stitching lines; hot-press molding: putting the sleeve that covered the case into the shoe mould, then use the hot press molding by putting the shoe into a high frequency hot press machine to get into shape.
 12. The method of claim 1, wherein the step of hot-press molding further including the steps of pre-heating, welding, and hot pressing.
 13. The method of claim 2, wherein the parameters of hot-press molding are pre-heating for 0 to 10 seconds, welding for 15 to 35 seconds, hot pressing under temperature of 150° C. to 280° C. for 5 to 10 seconds.
 14. The method of claim 2, wherein the shoe mould includes four detachable portions, which are upper mould, lower mould, right mould and left mould.
 15. The method of claim 4, wherein the steps of pre-heating, welding, and hot pressing further including pre-heating, welding, and hot pressing on upper and lower moulds, pre-heating, welding, and hot pressing on right and left moulds.
 16. The method of claim 5, wherein the parameters of pre-heating, welding, and hot pressing on upper and lower moulds are as pre-heating for 0 to 5 seconds, welding for 0 to 15 seconds, hot pressing under temperature of 150° C. to 280° C. for 0 to 5 seconds.
 17. The method of claim 5, wherein the parameters of pre-heating, welding, and hot pressing on right and left moulds are as pre-heating for 0 to 5 seconds, welding for 0 to 20 seconds, hot pressing under temperature of 150° C. to 280° C. for 0 to 5 seconds.
 18. The method of claim 1, wherein the pre-designed shoe pattern is toed shoe pattern.
 19. The method of claim 8, wherein the toed shoe pattern has one toe, two toes, three toes, four toes or five toes.
 20. The method of claim 8, wherein the distribution of the stitching lines on the toes is along the direction from toe cap to toe wrap. 